Page 1

ZX 75

Book 22990683 (10-02-06) Rev. A

Service Manual

Printed in U.S.A. 2006


SAFETY & MAINTENANCE

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

HYDRAULIC SYSTEM

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX INGERSOLL RAND EXCAVATOR IDENTIFICATION . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 UNDERCARRIAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01 ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

UNDERCARRIAGE UPPERSTRUCTURE & SWING SECTION ELECTRICAL SYSTEM AND ANALYSIS ENGINE SERVICE

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 70-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

HVAC

SPECIFICATIONS

Spec-01-I

Book 22990683 (10-02-06) Rev. A


FOREWORD This manual is for the Ingersoll Rand Hydraulic Excavator mechanic. It provides necessary servicing and adjustment procedures for the hydraulic excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc. A general inspection of the following items must be made after the hydraulic excavator has had service or repair:

1. Check that the ROPS/TOPS/ FOPS is in good condition and is NOT modified.

9. Safety treads must be in good condition.

2. Check that ROPS mounting hardware is tightened and is Ingersoll Rand approved.

10. Check for correct function of indicator lamps (Optional on some models.

3. The seat belt must be correctly installed, functional and in good condition.

11. Check hydraulic fluid level, engine oil level and fuel supply.

4. Inspect for loose or broken parts or connections.

12. Inspect for fuel, hydraulic fluid leaks.

5. Machine signs must be legible and in the correct location.

13. Lubricate the excavator.

6. Steering levers, control levers and foot pedals must return to neutral. Check that foot pedals lock and control lever locks are in working order.

14. Check the condition of the battery and cables.

7. Inspect the air cleaner for damage or leaks. Check the condition of the element.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

8. Check the electrical charging system.

oil

or

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are know to the state of California to cause cancer, birth defects and other reproductive harm.

Spec-01-III

Book 22990683 (10-02-06) Rev. A


The following publications provide information on the safe use and maintenance of the Ingersoll Rand machine and attachments:

SAFETY INSTRUCTIONS

Safety Alert Symbol This symbol with a warning statement means: ì Warning, be alert! Your safety is involved!î Carefully read the message that follows.

ï

The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

ï

The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Ingersoll Rand dealer.

ï

Machine signs (decals) instruct on the safe operation and care of your Ingersoll Rand machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Ingersoll Rand dealer.

ï

An Operatorís Handbook fastened to the operator cab. Itís brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Ingersoll Rand dealer for more information on translated versions.

ï

The AEM Safety Manual delivered with the machine gives general safety information.

ï

The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.

WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operatorís Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine.

Spec-01-V

Book 22990683 (10-02-06) Rev. A


SAFETY INSTRUCTIONS (CONTíD)

ï

Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

ï

Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).

Fire Prevention The machine and attachments have components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Figure 1

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential hazard. The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot. ï

Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

ï

The operator cab, engine compartment, and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

ï

Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

ï

Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

ï

Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure you or bystanders.

ï

Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.

ï

Stop the engine and let it cool before adding fuel. NO SMOKING!

ï

Spec-01-VII

Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Ingersoll Rand dealer [Figure 1].

Book 22990683 (10-02-06) Rev. A


SERIAL NUMBER LOCATIONS

Engine Serial Number

Always use the serial number of the excavator when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

Figure 2

1

Excavator Serial Number Figure 1

S/N 528911001 & Above S/N 528611001 & Above

P-56395

The engine serial number (Item 1) [] & [Figure 2] is located on the engine in the locations shown. 1

The excavator serial number plate (Item 1) is located on the frame of the machine in the location shown [Figure 1]. Explanation of Excavator Serial Number: XXXX

XXXXX Module 2. - Production Sequence (Series) Module 1. - Model / Engine Combination

1. The four digit Model/Engine Combination Module number identifies the model number and engine combination. 2. The five digit Production Sequence Number identifies the order which the excavator is produced.

Spec-01-IX

Book 22990683 (10-02-06) Rev. A


DELIVERY REPORT Figure 3

The delivery report must be filled out by the dealer and signed by the owner or operator when the Ingersoll Rand Excavator is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 3].

Spec-01-X

Book 22990683 (10-02-06) Rev. A


INGERSOLL RAND EXCAVATOR IDENTIFICATION ARM CYLINDER BOOM

ARM

OPERATOR HANDBOOK

OPERATOR SEAT With SEAT BELT

BOOM CYLINDER

HI FLOW RETURN COUPLER

GRAB HANDLE

AUXILIARY COUPLERS BUCKET CYLINDER

BUCKET

BLADE CYLINDER

RIGHT SIDE COVER

REAR COVER

AUXILARY COUPLERS

UPPERSTRUCTURE

BLADE

TRACK

TRACK FRAME

Spec-01-XI

Book 22990683 (10-02-06) Rev. A


MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operatorís Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: ì Warning, be alert! Your safety is involved!î Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

CORRECT

Never service the Ingersoll Rand Hydraulic Excavator without instructions.

WRONG

Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

WRONG

Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust machine with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.

Use the correct procedure to lift and support the excavator. Always lift the blade fully before installing jackstands.

Cleaning and maintenance are required daily.

WRONG

WRONG

Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust Fumes can kill without warning.

Always lower the bucket and blade to the ground before doing any maintenance. Never modify equipment or add attachments not approved by Ingersoll Rand.

WRONG

WRONG

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep tailgate closed except for service, Close and latch tailgate before operating the excavator.

Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED INGERSOLL RAND SERVICE PERSONNEL. Always use genuine Ingersoll Rand replacement parts.


SPECIFICATIONS CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-1 Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-1 U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-2 EXCAVATOR BOLT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1

SAFETY & MAINTENANCE SPECIFICATIONS

FUEL, COOLANT AND LUBRICANTS (CONTíD) . . . . . . . . . . . . . . . . SPEC-70-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1 HYDRAULIC EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . SPEC-10-1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 Digging Force. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5

DRIVE SYSTEM

ELECTRICAL SYSTEM & ANALYSIS ENGINE SERVICE

HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1

Spec-01-1

Book 22990683 (10-02-06) Rev. A


HYDRAULIC EXCAVATOR SPECIFICATIONS Machine Dimensions ï

All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

ï

Where applicable, specifications conform to SAE or ISO standards. Specifications are subject to change without notice.

243î (6170) 1710î (9340)

205î (5195) 107î (272)

167î (4250)

104î (2639)

286î (7260)

Spec-10-1

B-16806

Book 22990683 (10-02-06) Rev. A


HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTíD) Performance Operating Weight w/Cab 24î Bucket, rubber tracks)

16534 lbs (7500 Kg)

Travel Speed Low

1.7 MPH (2,7 km/hr.)

High

3.2 MPH (5,2 km/hr.)

Controls Vehicle

Two Hand or Foot Levers control speed & direction. RH console switch controls 2 speed travel.

Excavator Functions

Right and left joysticks control boom, arm, bucket, arm and swing. RH thumb switch controls auxiliary hyd. LH foot pedal controls boom swing Separate hand lever controls blade.

Spec-10-2

Book 22990683 (10-02-06) Rev. A


HYDRAULIC EXCAVATOR SPECIFICATIONS Engine Make

Deutz

Model

BF4M 2011

Fuel

Diesel/Liquid (Oil cooled)

Horsepower

73 HP (54 kW) @ 2200 RPM

Maximum Governed RPM (Full Load)

NA

Maximum Torque

NA

High Idle RPM

2200

Low Idle RPM

900

No. of Cylinders

Four

Displacement

190 cu.in. (3108 cm)

Bore x Stroke

3.7 (94 mm) X 4.4 (112 mm)

Lubrication

Pressure System W/Filter

Filter

Cartridge type - Full Flow

Air Cleaner

Dry replaceable paper cartridge, dual element

Electrical Starter

12 Volt (2,0 kW) Reduction Drive

Alternator

14 Volt, 55 Amps, open, negative ground

Battery

12 Volt, 450 Cold Crank Amps. @ 0∞F (-18∞C)

Hydraulic System Variable Displacement Piston Pump

37.5 GPM (142 L/min)

Gear Pumps (2 combined)

17.4 GPM (66 L/min)

System Relief Settings -Gear Pump

3335 PSI (230 bar)

-Piston Pump

4060 PSI (280 bar)

Swing Blade And Boom Swing Circuits

3335 PSI (230 bar)

Bucket, Arm, Boom and Travel Circuits

4060 PSI (280 bar)

Auxiliary Flow Control Valves

26.42 GPM (100 LPM) Three Spool Open Center Valve, Six Spool Closed Center

Drive Motors

2 Axial Piston

Swing Motor

Piston Motor

Spec-10-3

Book 22990683 (10-02-06) Rev. A


HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTíD) Hydraulic System Variable Displacement Piston Pump

41.2 GPM (156 L/min)

Gear Pumps (2 combined)

17.9 GPM (68 L/min)

System Relief Settings -Gear Pump

3335 PSI (230 bar)

-Piston Pump

4060 PSI (280 bar)

Swing Blade And Boom Swing Circuits

3335 PSI (230 bar)

Bucket, Arm, Boom and Travel Circuits

4060 PSI (280 bar)

Auxiliary Flow Control Valves

26.4 GPM (100 LPM) Three Spool Open Center Valve, Six Spool Closed Center

Drive Motors

2 Axial Piston

Swing Motor

Piston Motor

Hydraulic Cycle Times Bucket

Curl 2.2 sec.

Arm

Dump 2.7 sec.

Retract 3.5 sec.

Extend 4.2 sec.

Boom

Raise 6.5 sec.

Lower 5.9 sec.

Boom Offset

Left 9.7 sec.

Right 9.7 sec.

Blade

Raise 2.2 sec.

Lower 2.2 sec.

Swing System Swing Drive

Radial Piston Motor W/Brake

Swing Circle

Single Row Shear Type Ball Bearings With Internal Gear

Swing Speed

10 RPM

Hydraulic Cylinders Cylinder

Bore Dia. in. (mm)

Rod Dia. in. (mm)

Stroke in. (mm)

Boom

4.7î (120 mm)

2.4î (60 mm)

33.5î (850 mm)

Arm

4.5î (115 mm)

2.8î (70 mm)

26.4î (670 mm)

Bucket

3.5î (90 mm)

2.4î (60 mm)

28.3î (720 mm)

Boom Swing

4.1î (105 mm)

2.4î (60 mm)

24.6î (625 mm)

Blade

3.9î (100 mm)

2.0î (50 mm)

7.9î (200 mm)

Spec-10-4

Book 22990683 (10-02-06) Rev. A


HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTíD) Drive System Final Drive

Each Track is Driven by an Axial Piston Motor

Type of Reduction

Two Stage Planetary Gear Reduction

Max. Drawbar Pull

13613 lbs. (60.5 KN))

Gradability Brakes

60%

Travel

NA

Service & Parking

NA

Swing Service

NA Spring loaded multi disc brake applied when control lever is in neutral

Parking Undercarriage Type

NA

Crawler-Tractor Design, Sealed Track Rollers W/Box-Section Track Roller Frame. Grease Type Track Adjusters W/Shock Absorbing Recoil Springs.

Track Type

Rubber (Standard)

Steel (Optional)

Width

18 inch (457 mm)

NA

NA

42

7

7

4.1 PSI (0.28 bar)

4.23 PSI (0.29 bar)

No. of Shoes No. of Track Rollers Ground Pressure

Spec-10-5

Book 22990683 (10-02-06) Rev. A


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